Jungheinrich EJE 116, Operating Instructions Manual

Page 1: ...1 2 3 4 5 6 7 8 9 0 Set Operating instructions 50425855 EJE 116 118 120 G 10 03 06 06...

Page 2: ...explanations are indicated by the following graphics F Used before safety instructions which must be observed to avoid danger to personnel M Used before notices which must be observed to avoid materi...

Page 3: ...0108 GB...

Page 4: ...ion and commissioning 1 Transportation by crane C 1 2 Commissioning C 1 3 Moving an incapacitated truck C 2 3 1 Emergency operation with service key 741 o C 3 D Battery Servicing recharging replacemen...

Page 5: ...lift truck 1 Operational safety and environmental protection F 1 2 Safety regulations applicable to truck maintenance F 1 3 Servicing and inspection F 3 4 Maintenance Check list EJE 116 118 120 F 4 5...

Page 6: ...06 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instruct...

Page 7: ...0506 GB 2...

Page 8: ...lf or on whose behalf it is used In special cases e g leasing or renting the user is consid ered the person who in accordance with existing contractual agreements between the owner and the user of the...

Page 9: ...0600 GB A 2...

Page 10: ...support or with lateral boards outside of the area of the load bearing wheels or trolleys can be transported The load capacity can be found on the load capacity label Qmax Truck type load capacity an...

Page 11: ...Keyboard CANCODE 10 t Battery hood 3 t Key switch 11 t Controller o Key switch with an additional second stage for brake release 12 t Collision safety device 4 t Front cover 13 t Control shaft 5 t Dri...

Page 12: ...d 6 0 6 0 6 0 6 0 6 0 6 0 km h Lifting speed with without load 3 4 4 2 3 3 4 2 3 2 4 2 cm s Lowering speed with without load 5 3 3 6 5 3 3 6 5 3 3 6 cm s Max climbing capacity 5 min with without load...

Page 13: ...0803 GB B 4 h 13 Ast l1 l2 Q 150 40 1268 803 h 3 55 y c l a _ 2 a _ 2 700 b 5 b 11 e Wa...

Page 14: ...for electromagnetic emission and interference immu nity as well as testing of static electricity discharge ac cording to EN 12895 and the references to other standards contained therein Z Electrical...

Page 15: ...tion 16 Truck identification plate 17 Load capacity Qmax 18 Prohibition sign Do not ride on truck 19 Lifting point for crane transportation 20 Plate confirming accident prevention checks only D 1 2 3...

Page 16: ...pare parts please indicate the serial number 22 Item Designation Item Designation 21 Type 27 Manufacturer logo 22 Serial No 28 Min max battery weight in kg 23 Rated capacity in kg 29 Drive power in kW...

Page 17: ...0803 GB B 8...

Page 18: ...Commissioning M Only drive the truck under battery power A rectified alternating current damages the electronic components Cable con nections to the battery towing cable must be shorter than 6 m In o...

Page 19: ...cally operated brake must be released Remove the front hood 2 see Chapter F Remove the right hand drive cover 3 see Chapter F Screw on 2 off M4x20 bolts 4 to loosen the armature plate The truck can no...

Page 20: ...in the truck and connected Set service key 741 o 701 is standard to position 2 of the key switch Z Key 701 for normal truck operation can be turned to key switch position 1 only Press and hold the In...

Page 21: ...0606 GB C 4...

Page 22: ...cable shoes must be clean lightly greased with pole grease and must be securely tightened Batteries with bare terminal posts must be covered using a non skid insulating mat Disposal of the battery Ba...

Page 23: ...properly fixed in the bat tery compartment the truck 3 Batteries and motor output Z The abbreviations K short version and L long version on the identification plate indicate the present model Dependin...

Page 24: ...arg ing the surfaces of the battery cells must be exposed to provide sufficient aeration No metallic objects must be laid on the battery Before charging check all cable and plug connections for visibl...

Page 25: ...appropriate battery according to the following table M The power plug must be pulled before the corresponding charging curve is to be ad justed M Provided that a battery is connected a new setting can...

Page 26: ...lation mat from battery if necessary Battery plug must not be unplugged Connect power plug 6 with a power socket The flashing LED indicates the charging status and or a fault flashing codes see table...

Page 27: ...fault Indication is lit Recharge procedure is finished battery is full charging break fill up charge or equalization charge flashes slowly Charging process flashes fast Indicates the start of a recha...

Page 28: ...on the battery trough The crane equipment must pull vertically The hooks of the crane equipment must never fall onto the battery cells Expose the battery see Section 4 Remove the battery plug 3 Connec...

Page 29: ...e than 10 within 3 minutes The residual capacity displayed cannot rise while the truck is in operation The residual capacity display is reset to 100 when the battery type is defined Call the manufactu...

Page 30: ...uck or on the attach ments must immediately be brought to the notice of the person in charge fork lift trucks that cannot be safely operated e g due to worn tyres or defective brakes must not be used...

Page 31: ...thorised persons from switching on the truck Key switch with second position o Releases the brake to allow a non operable truck to be moved 6 Integrated charging device incl safety circuit o Charges t...

Page 32: ...E 3 0606 GB 1 2 3 4 5 6 7 8 0 9 S e t 5 4 3 2 1 6 7 12 8 8 9 11 10...

Page 33: ...der and the cable connections Switching on the truck Check that the battery plug 2 is plugged in Insert the key in the key switch 5 and turn it all the way to the right to position I or enter the CANC...

Page 34: ...d inclines Negotiating of slopes and inclines is permitted only when they are recognised lanes when they are clean and non slipping and when the technical specification of the truck permits safe drivi...

Page 35: ...he controller 8 Lower the control shaft 1 into the travel direction F and set the drive controller 8 to the desired direction V or R forward or backward Inching F The driver must be particularly caref...

Page 36: ...E 7 0606 GB Steering Swing the control shaft 1 to the left or right 1 2 3 4 5 6 7 8 9 0 Set 0 R R V B F B V 8 1 7...

Page 37: ...ed to switch to the opposite direction The truck is braked by the countercurrent until driving in the opposite direction takes affect Braking with the coasting brake The truck is braked with the regen...

Page 38: ...ice pushbutton 10 for left handed operation o 13 until the desired height is reached m Release the button immediately when the end stop of the load lifting device is reached Lowering Press the Lower l...

Page 39: ...eters only in conjunction with the indicator instrument CANDIS o The o key has top priority and reset the truck from any condition to the basic condition without modifying any settings 5 1 Code lock A...

Page 40: ...up red When an incorrect code has been entered LED 15 lights up red for two seconds After that you can enter a new code Z The Set key 16 has no function in operating mode Switching off The truck is sw...

Page 41: ...e setting of the code lock func tions and the adaption of the travel programmes Additionally the battery parameters can be set Z For trucks without indicator instrument CANDIS o only the code lock par...

Page 42: ...ehaviour is changed you must perform a trial in a specially assigned and suitable working area run after changing any of the parameters Entering the master code Press the o key Enter master code Code...

Page 43: ...rminate the input press the o key 20 The following parameters can be entered Code lock parameter list No Function Range Setting value Default Setting value Comments Work flow Code lock 000 Change mast...

Page 44: ...Confirm Set LED 18 flashes Enter a new code Confirm Set LED 19 flashes Repeat the code en try Confirm 003 Delete operator code 0000 9999 or 00000 99999 or 000000 999999 LED 18 flashes Enter a code Con...

Page 45: ...o an existing code Operator code to be deleted does not exist Code memory full No Function Range Setting value Default Setting val ue Comments Work flow Code lock 021 Travel programme 1 Enable 0 or 1...

Page 46: ...with the Set key 16 The LED 15 of the o key 20 switches briefly to steady light and start flashing again after approx 2 seconds Z When the input is incorrect the LED 15 of the o key 20 lights up red A...

Page 47: ...4 8 km h depending on controller 108 Maximum speed in fork di rection via controller 0 9 2 8 6 2 km h 3 4 8 km h depending on controller No Function Range Setting value Standard Setting val ue Commen...

Page 48: ...tting val ue Comments Travel Programme 3 301 Acceleration 0 9 0 2 2 0 m s2 9 2 0 m s2 302 Coasting brake 0 9 0 2 2 0 m s2 9 1 1 m s2 304 Maximum speed in drive direction via controller 0 9 2 8 6 2 km...

Page 49: ...dditional Warning 21 and Stop 23 indicators may result Number Bars Charging condition Wet battery Maintenance free battery LED yellow Warning LED red Stop LED yellow Warning LED red Stop 10 90 1 100 O...

Page 50: ...it error number If several errors occur they are displayed one after the other The errors are displayed as long as they are present always in combination Cxxx Exxx Errors are displayed as long as they...

Page 51: ...h in position 0 Incorrect CANCODE code Battery exhausted Fuse defective Truck is being charged Check the battery connector and connect if necessary Set the key switch to position I Verify code Check t...

Page 52: ...ians trained especially for these assignments We thus recommend signing a maintenance contract with the relevant service location of the manufacturer Lifting and jacking up When a fork lift truck is t...

Page 53: ...he quality of the tyres greatly affects the stability and the driving behaviour of the fork lift truck The factory mounted tyres must only be replaced by original spare parts of the manufacturer since...

Page 54: ...n single shift operation under normal op erating conditions For applications in dusty environments or involving large temper ature fluctuations or multiple shift operation the servicing intervals must...

Page 55: ...e if necessary k t Lifting device 6 1 Performance and adjustment check t 6 2 Perform sight check of rollers sliding elements and stops k t 6 3 Check fork tines and fork carrier for wear and damage k t...

Page 56: ...or damage renew if necessary t Lubrication 11 1 Grease the vehicle in accordance with the lubrication schedule l t General measure ments 12 1 Check the electrical system for a grounding fault t 12 2 C...

Page 57: ...g Gliding surfaces s Grease nipples Filler plug hydraulic oil b Filler plug gear oil a Drain plug gear oil Gear oil overflow filler neck and inspection plug Cold store usage Compound for cold store us...

Page 58: ...materials of different grades or qualitiies resp except if mix ing is expressively prescribed in these operating instructions Avoid spilling Spilt liquid must be removed immediately using a suitable b...

Page 59: ...be taken to prevent any dropping tilting or slipping of the fork or truck When lifting the truck the instructions contained in chapter Transportation and commissioning have to be observed When perfor...

Page 60: ...the front cover see Section 6 2 Check the correct value according to the table of all of the fuses if necessary re place fuses Item Designation Protection of Value 7 F10 Integrated charging device op...

Page 61: ...sioned for more than 6 months additional meas ures must be discussed with the Service Department of the manufacturer 7 1 Operations to be performed prior to decommissioning Thoroughly clean the fork l...

Page 62: ...ced by any company or economic circumstances The inspector must be adequately informed and experi enced to be able to assess the condition of the fork lift truck and the effectiveness of the safety in...

Page 63: ...0606 GB F 12...

Page 64: ...tive tubular plates type EPzS and EPzB 2 6 Type plate Jungheinrich traction battery 7 Instruction for use Aquamatic BFS III water refilling system 8 12 2 Jungheinrich traction battery Maintenance free...

Page 65: ...d clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 50272 3 DIN 50110 1 No smoking Do not expose batteries to naked flames glowing embers or sparks as...

Page 66: ...ucks is the standard which ap plies to the operation traction batteries in industrial trucks 2 1 Discharging Be sure that all breather holes are not sealed or covered Electrical connections e g plugs...

Page 67: ...The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 68: ...ound further testing and maintenance by the service department should be requested 3 4 Annually In accordance with DIN VDE 0117 at least once per year the insulation resistance of the truck and the ba...

Page 69: ...be taken into account when considering the life of the battery 6 Malfunctions If malfunctions are found on the battery or the charger our service department should be called in without delay The meas...

Page 70: ...l battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer s logo 14 Safety instructions and warnings Typ 1 T ype Nennspannung 5 Nomin...

Page 71: ...sing batteries which comply with I and II it is important to follow the in structions on maintaining the respective protection class during operation see asso ciated certification Cell series Aquamati...

Page 72: ...d by means of a central sealing coupler through the hose connections in the individual Aquamatic BFS plugs 2 Application The Aquamatic BFS battery water refilling system is used in traction batteries...

Page 73: ...surface 5 2 Pressurised water The pressure reducing valve in the Aquamatic System is set from 0 2 bars to 0 6 bars and from 0 3 bars to 1 8 bars in the BFS system 5 3 Water Refill Trolley serviceMobi...

Page 74: ...ve a diagnostics hole with a 6 5 mm diameter Aquamatic plugs or a 7 5 mm diameter BFS plugs 9 2 Float Different floats are used depending on the cell design and type 9 3 Cleaning The plug systems may...

Page 75: ...en tral supply pipe This is connected to the water supply system at the battery charging station by means of a sealing coupler system On the battery side a closing nipple ident no 50219538 is mounted...

Page 76: ...battery Work on batteries to be carried out by skilled personnel only Use protective glasses and clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 5027...

Page 77: ...g plugs must only be made or broken in the open circuit condition To achieve the optimum life for the battery operating discharges of more than 60 of the rated capacity should be avoided deep discharg...

Page 78: ...0 0171 Ex I in areas with a firedamp hazard or Ex II in potentially explosive areas The attention pictograms has to be respected 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 79: ...1000 4 Care of the battery The battery should always be kept clean and dry to prevent tracking currents Clea ning must be done in accordance with the ZVEI code of practice The Cleaning of Vehicle Trac...

Page 80: ...raction battery CE mark is only for batteries with a nominal voltage greater than 75 volt Item Designation Item Designation 1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin material 3 Battery...

Page 81: ...0506 GB 18...